Protective case and methods of making

ABSTRACT

Disclosed is a protective case for an electronic device. The protective case has three layers: an elastomeric liner that surrounds a portion of the electronic device, a cover and a cushion insert disposed between the liner and cover. The cushion insert includes raised impact portions that extend through the cover, and that are capable of absorbing shocks from impacts.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims foreign priority under 35 U.S.C. §119(e)to commonly owned and co-pending U.S. Provisional Application No.61/698,563, which was filed on Sep. 7, 2012, the subject matter of whichis incorporated herein by reference in its entirety.

TECHNICAL FIELD

The present invention relates generally to cases designed to protectsensitive items from damage and/or to provide an exterior surface thatis comfortable to touch.

BACKGROUND

Numerous different types of electronic devices currently exist forcommunication, entertainment and other purposes. These include cellphones, MP3 players, video players, smartphones, communication devices,such as walkie-talkies, navigation devices, such as GPS devices, andother types of electronic devices, such as various types of computers,including laptop computers, hand-held computers, ultra-mobile computersand tablet computers. These devices often include touch screens,interactive panels including, but not limited to, capacitive coupledinterfaces, keyboards, scroll wheels, tilt switches, push buttonswitches, and other interactive controls. Due to the sensitive nature ofthese electronic devices, it is desirable to provide protection forthese devices.

SUMMARY

Disclosed herein, in one embodiment, is a protective case. Theprotective case comprises a cover having a back portion and a sidewallconnected to the back portion. The cover includes interconnected supportmembers defined by a plurality of receiving apertures disposed inpredetermined areas, and has a predetermined thickness. The case alsoincludes a liner having a back portion and a sidewall connected to theback portion. The cover and liner each have a predetermined thickness.The case also includes a cushion insert with raised impact regionsdisposed adjacent to first recessed impact regions. The raised impactregions are disposed in predetermined areas corresponding to theplurality of receiving apertures, and have a predetermined thicknessgreater than the thickness of the cover. The cushion insert is disposedbetween the cover and the liner, such that the plurality ofinterconnected support members engage with the first recessed impactregions, and the raised impact regions engage with the plurality ofreceiving apertures, such that the raised impact regions extend abovethe outer surface of the cover.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the Figures, the features and advantages of the presentdisclosure will be apparent from the following more particulardescription of exemplary embodiments, as illustrated in the accompanyingdrawings, in which like reference characters refer to the same partsthroughout the different views. The drawings are not necessarily toscale, emphasis instead being placed upon illustrating the principles ofthe disclosure.

FIG. 1 is a perspective front view of an exemplary protective caseaccording to the present disclosure, in an assembled configuration;

FIG. 2 is perspective back view of the cover of the protective caseshown in FIG. 1;

FIG. 3 is a side view of the protective case shown in FIG. 1;

FIG. 4 is an exploded perspective view of the protective case shown inFIG. 1;

FIG. 5 is a partial perspective cross-sectional view of the protectivecase shown in FIG. 1, through line 5-5;

FIG. 6 is an exploded view of the cross-section shown in FIG. 5;

FIG. 7A is a cross-section of one embodiment of the cushion insert shownin FIG. 4, which is not drawn to scale;

FIG. 7B is a cross-section of another embodiment of the cushion insertshown in FIG. 4, which is not drawn to scale;

FIG. 8 is a perspective front view of another exemplary protective caseaccording to the present disclosure, in an assembled configuration andmounted on a cell phone;

FIG. 9 is a perspective back view of the protective case shown in FIG.8;

FIG. 10 is an exploded perspective view of the protective case shown inFIG. 8;

FIG. 11 is an exploded cross-sectional view of the protective case shownin FIG. 8;

FIG. 12 is an exploded perspective view of one section of the protectivecase shown in FIG. 8;

FIG. 13 is an exploded perspective view of one section of the protectivecase shown in FIG. 8;

FIG. 14 is an exploded perspective view of the two sections of shown inshown in FIGS. 12 and 13, each in an assembled configuration;

FIG. 15 is a cross-section of screen protector and liner of theprotective case shown in FIG. 8, mounted on a cell phone;

FIG. 16 is a cross-section of the cover and liner of the protective caseshown in FIG. 8, in an assembled configuration;

FIG. 17 is a cross-section of the protective case shown in FIG. 8;

FIG. 18 is a front view of another embodiment of a protective caseaccording to the present disclosure;

FIG. 19 is an interior view of the protective case shown in FIG. 18;

FIG. 20 is a side view of the protective case shown in FIG. 8; and

FIG. 21 is a cross-sectional view of the protective case shown in FIG.18.

DETAILED DESCRIPTION

The present disclosure is directed to protective impact absorbing andcushioning structures designed to protect sensitive items from damage.The present structures can conform to the contours of the items to beprotected, and provide an exterior surface that is comfortable to touch.The present structures include, in some embodiments, both raised andrecessed impact regions of various shapes, sizes, configurations andthicknesses. Various materials can be used for the raised impactregions, as will be described below.

The improved cases of the present disclosure comprise interconnected butseparable case sections that substantially conform to the outer surfaceof the item to be protected. The case can be designed to have specificfunctional characteristics such as, for example, targeted impactprotection on case edges and corners. By combining specific shapes,sizes, configurations, contours and orientations of raised and recessedimpact regions, the case can be adapted for any type of product thatrequires protection, in addition to those mentioned above.

For example, the present cases can be adapted into sleeves or cases thatcorrespond to the shape and size of an electronic device, such as alaptop computer or a tablet device, such that they conform to theexterior of the case. As such, the case can be formed in shapes thatwould conform at least in part to the outer surface of the encasedproduct. The cases described herein also may be adapted for luggage,athletic protective gear, and the like.

The protective cases can provide lightweight and flexibleimpact-resistant protection, and can be aesthetically pleasing, moredurable and lower in cost than other cases. For ease of discussion, theterm “flexible,” as used herein, means the ability of the pad to move bybending, twisting, flexing and/or stretching, and the like. Theconstruction of the present cases is rugged, durable, and able towithstand the temperatures, detergents and mechanical action used inindustrial and/or commercial laundering, unlike other cases, which maydegrade under such harsh conditions.

FIGS. 1-7, when taken together, show one exemplary embodiment of thepresent disclosure, which is directed to a protective case 10 for anelectronic device (not illustrated), such as a media device or cellphone. Although described herein with reference to a protective case foran electronic device, as noted above, the protective case may be adaptedto any product that requires protection or that is designed to provideprotection. For ease of reference, in all of the embodiments disclosedherein, the electronic device will be referred to hereinafter as a cellphone.

Case 10 is shown in an assembled configuration in FIG. 1, and in anexploded view in FIG. 4. As shown, case 10 comprises a cover 12, acushion insert 30, and a liner 40, which may be interconnected whenassembled, as shown in FIG. 1, but are otherwise separable from oneanother, as shown in FIG. 4. In the present embodiment, cover 12,cushion insert 30 and liner 40 are each single, unitary parts, but ifdesired, each may be formed as two or more separable but interlockingparts that can be assembled together and/or onto the surfaces of thecell phone.

Cover 12 may be constructed to conform to the exterior surface of atleast a portion of the cushion insert 30. Cover 12 comprises a backsection 14 and a sidewall 16 extending upwardly from the back section14. Each of the back section 14 and sidewall 16 comprise opposing innersurfaces 14 a, 16 a and outer surfaces 14 b, 16 b respectively.

One or both of the back section 14 and sidewall 16 comprises a pluralityof receiving apertures 22 extending from the inner surfaces 14 a, 16 ato the outer surface 14 b, 16 b, to define a plurality of interconnectedsupport members 24 disposed between the receiving apertures 22.

The cover 12 may be formed of a substantially rigid, semi-rigid and/orflexible material, and has a size and configuration corresponding to thecell phone. When rigid or semi-rigid, it may be desirable for the cover12 to comprise two or more separable but interlocking parts that can beassembled onto the front and rear surfaces of the cell phone. The cover12 can be made from a material that is capable of stretchingsufficiently to allow the electronic device to slide into the frontopening 20 of the cover 12 while maintaining the form-fitting shape ofthe cover 12. Suitable materials include, but are not limited to, avariety of thermoset materials, such as synthetic rubber, silicon,urethane and other materials. The density and elasticity of the cover12, as well as the pre-forming of the cover 12 to fit the shape ofelectronic device, allows the material of the cover 12 to both stretchand recover so that the cushion cover fits tightly on the electronicdevice. In the present embodiment, cover 12 is a unitary pre-formedelastomeric material that is flexible and capable of stretchingsufficiently to allow the electronic device to slide easily into and beremoved from case 10. The cover 12 has sufficient elasticity to stretchover the electronic device, and to recover so that the cover fits snuglyover the cushion insert and on the electronic device, such that the case10 conforms to the electronic device. The cover 12 can be formed using avariety of techniques and processes suitable for processing theforegoing materials, which are known in the art.

In the present embodiment, cover 12 has a predetermined thickness T₁that is selected to be less than the thickest section of the cushioninsert T_(2,) as will be described below. In the present embodiment, thethickness T₁ ranges from about 0.050″ to about 0.090″, more particularlyabout 0.060″ to about 0.080″, more particularly still about 0.075″.

The liner 40 may be constructed to conform to the interior surface of atleast a portion of cover 12 and cushion insert 30. The liner comprises aback section 44, a sidewall 46 extending upwardly from the back section44, and a bezel 48 extending outwardly from the sidewall 46 to definethe front opening 20.

The liner 40 may be formed of a substantially flexible material, and hasa size and configuration corresponding to the cell phone. The liner 40can be made from any of the materials described above with reference tothe cover 12, provided the material is capable of stretchingsufficiently to allow the electronic device to slide into the frontopening 20 of the liner 40 while maintaining the form-fitting shape ofthe liner 40. In the present embodiment, liner 40 is unitary, and cancomprise an elastomeric material as described above with reference tothe cover 12, which is flexible and capable of stretching sufficientlyto allow the electronic device to slide easily into and be removed fromliner 40. The liner 40 has sufficient elasticity to stretch over theelectronic device, and to recover so that the cover fits snugly over thecushion insert and on the electronic device, such that the liner 40 andtherefore the case 10 conforms to the electronic device. The density andelasticity of the liner 40, as well as the pre-forming of the liner 40to fit the shape of electronic device, allows the material of the liner40 to both stretch and recover so that the cushion cover fits tightly onthe electronic device. The liner 40 can be formed using a variety oftechniques and processes suitable for processing the foregoingmaterials, which are known in the art.

The cushion insert 30 may be constructed to conform to at least aportion of the outer surface of the liner. The cushion insert 30 may beformed from a variety of materials, such that it has a size andconfiguration corresponding to a portion of the inner surface of thecover and a portion of the outer surface of the liner, and a thicknessthat allows it to fit between the inner surface of the cover and theouter surface of the liner 40.

FIG. 7 shows an exemplary embodiment of cushion insert 30, whichcomprises spaced apart top and bottom surfaces 30 a,b and a plurality ofraised impact regions 32 disposed adjacent to first recessed impactregions 34. The raised impact regions 32 are defined in and extendupwardly from the top surface 30 a, and are disposed in predeterminedareas corresponding to the plurality of receiving apertures 22 andhaving a width W₁, which may vary as desired, and a predeterminedthickness T₂ that is selected to be greater than the thickness T₁ of thecover 12. In the present embodiment, the width W₁ of the raised impactregions 32 is about 0.200″ to about 0.400″, more particularly about0.250″ to about 0.350″, and more particularly still about 0.305″; andthe thickness T₂ ranges from about 0.150″ to about 0.350″, moreparticularly about 0.200″ to about 0.300″, more particularly still about0.240″.

Raised impact regions 32 are spaced apart from one another by firstrecessed impact regions 34. First recessed impact regions 34 have awidth W₂, which may vary as desired, and a predetermined thickness T₃,which is selected to be less than the thickness T₂ of the raised impactregions 32. In the present embodiment, the width W₂ of the firstrecessed regions 34 is about 0.100″ to about 0.200″, more particularlyabout 0.130″ to about 0.170″, and more particularly still about 0.150″;and the thickness T₃ ranges from about 0.025″ to about 0.045″, moreparticularly about 0.030″ to about 0.040″, and more particularly stillabout 0.035″.

The cushion insert 30 also may comprise one or more second recessedimpact regions (not illustrated) that correspond to the contours, edgesand/or corners of the cell phone, to facilitate bending and/or flexingof the cushion insert 30 into the contours, edges and/or corners ofcover 12. When present, the second recessed impact regions 36 have awidth W₃, which may vary as desired, and a predetermined thickness T₄,which is selected to be less than the thickness T₃ of the first recessedimpact regions 36. In the present embodiment, the width W₃ of the secondrecessed regions 36 is about 0.080″ to about 0.200″, more particularlyabout 0.100″ to about 0.170″, and more particularly still about 0.132″;and the thickness T₃ ranges from about 0.010″ to about 0.030″, moreparticularly about 0.015″ to about 0.025″, and more particularly stillabout 0.020″. When assembled, the raised impact regions 32 protrude orextend above the outer surface of cushion insert 30 by a distance D₁, asshown in FIG. 5.

All of the foregoing thicknesses, widths, distances and spacings mayvary, as desired.

In the present embodiment, the raised impact regions 32 comprise anupper surface 32 a and sidewalls 32 b extending downwardly therefrom.The raised impact regions 32 may have any thickness sufficient toprovide a protective or comfortable effect, by protruding above theexterior surface of the cover 12. Thus, for certain functionaladvantages, the thickness of the raised impact regions 32 may bedesigned to protrude above the outer surface of the case, when in anassembled configuration. For example, in the present exemplary cellphone device case 10, when assembled, the raised impact regions 32 mayprotrude or extend above the outer surface 12 a of the cover 12 by about1/16 inch to about ½ inch. If desired or needed, and as shown in thepresent embodiment, the cushion insert 30 also can comprise raisedimpact regions 32 designed to protrude through the sidewall or the bezelto protect the edges and/or screen from an impact.

The raised impact regions 32 may have any shape or configuration as isdesired to achieve the functional advantage of impact protection, or theaesthetic design intended to appeal to a consumer. The size, shape,quantity, configuration and location of the raised impact regions may bevaried as desired in order to achieve the foregoing objectives. Foraesthetic purposes, the color of the cover and cushion insert may be thesame or different, and also may include text and/or graphics.

Each of the cover 12, liner 40 and insert 30 may comprises one or moreraised keys 28 that correspond in shape, size and location to the size,shape and location of smaller functional keys or ports (also notillustrated herein) to which access may be limited due to the thicknessof the case, to allow the user to maintain functional access withoutremoving the case from the electronic device. Examples of such smallerfunctional keys include, but are not limited to, power and volume keys.Raised keys 28 should not be confused with the raised impact regions 32,which are intended to absorb impacts.

Similarly, each of the cover 12, liner 40 and insert 30 may comprise oneor more functional apertures 26 or holes that correspond in shape, sizeand location to the size, shape and location of various functional keys,ports, devices or other items that may be included on the electronicdevice (none of which are illustrated herein), to keep such items freeof obstruction. Examples of such functional keys include, but are notlimited to, charging ports, speakers, auxiliary ports, power keys,camera lenses, and the like.

The cushion insert 30 also optionally may comprise one or moreperforations (not illustrated) formed in the second recessed impactregions, or elsewhere as desired, to facilitate ease and conformance ofthe cushion insert 30 between the cover 12 and liner 40.

To assemble the case, the cushion insert 30 may be inserted into cover12 such that the raised impact regions 32 are aligned with the receivingapertures 22 such that the raised impact regions 32 are received intoand extend at least partially therethrough the corresponding receivingapertures 22, and a portion of the raised impact regions 32 extendsabove the upper surface 12 a of the cover 12.

When assembled, the raised impact regions 32 protrude from thecorresponding receiving apertures 22 on the cover 12, and the firstrecessed impact regions 34 between the raised impact regions 32 aredisposed underneath the support members 24, between the raised impactregions 32. The protruding raised impact regions 32 function at least toprotect the cover and electronic device from impact, and the first andsecond recessed impact regions 34 disposed underneath the cover 12 alsoabsorb energy through the material disposed between the device and thecover. Thus, the case 10 provides impact resistance and energyabsorption, as a result of the externally exposed raised impact regions32 and portions of the cushion insert 30 that are disposed underneaththe cover 12, adjacent to the electronic device. Although illustratedherein with receiving apertures 22 adapted to receive raised impactregions 32 therein, cover 12 also can be formed to comprise recessedregions 38, rather than apertures, to receive the raised impact regions32 therein.

FIGS. 8-17, when taken together, show another exemplary embodiment of aprotective case 100 according to the present disclosure. As in theprevious embodiment, although described herein with reference to aprotective case for an electronic device, the protective case may beadapted to any product that requires protection or that is designed toprovide protection. For ease of reference, the electronic device will bereferred to hereinafter as a cell phone.

As shown, case 100 comprises a cover 12′, a cushion insert 30, and aliner 40′, which may be interconnected when assembled, but are otherwiseseparable from one another. In the present embodiment, cover 12′,cushion insert 30, and liner 40′, are each single, unitary parts, but ifdesired, each may be formed as two or more separable but interlockingparts that can be assembled together and/or onto the surfaces of thecell phone.

Cushion insert 30 has the same construction as in the previousembodiments.

Liner 40′ may be constructed to conform to the interior surface of atleast a portion of cover 12′ and cushion insert 30. The liner 40′comprises a back section 44, a sidewall 46 extending upwardly from theback section 44, and a bezel 48 extending outwardly from the sidewall 46to define the front opening 20.

Cover 12′ comprises a back section 14, sidewalls 16 extending upwardlyfrom the back section 14, and one or more retaining arms 70 extendinginwardly from one or more of the sidewalls 16. Each of the back section14 and sidewall 16 comprise opposing inner surfaces 14 a, 16 a and outersurfaces 14 b, 16 b respectively.

When assembled, the retaining arms 70 assist in retaining the bezel 48and liner against the cell phone when the cell phone is disposed in theprotective case.

FIGS. 18-21, when taken together, show another exemplary embodiment of aprotective case 200 according to the present disclosure.

As shown, case 200 comprises a cover 12 and a cushion insert 30, and anoptional liner 40 (not illustrated). In the present embodiment, cover12, cushion insert 30 and optional liner 40 are each single, unitaryparts, but if desired, each may be formed as two or more separable butinterlocking parts that can be assembled together and/or onto thesurfaces of the cell phone. Cushion insert includes receiving apertures22 in which raised impact regions 32 have been disposed, to provideimproved protection on the front or screen side of the cell phone. Theraised impact regions can comprise part of a cushion insert 30 thatconforms to the interior of the cover, as in previous embodiments, orthey can be individual regions that are disposed in the receivingapertures.

Optionally, in any of the foregoing embodiments, two or more of thecover, liner and inserts may be co-molded, welded, bonded or adheredtogether using a variety of techniques.

The thickness of cushion insert 30 may be varied as desired, but it isdesirable for the thickness to be sufficient to protect the device fromimpact, while remaining thin enough to minimize the total weight of thecase

Various other materials and layers may be used to form the cushioninginserts, as described in commonly-owned and co-pending U.S. applicationSer. No. 13/447,093, which was filed on Apr. 13, 2012, and isincorporated herein by reference in its entirety. Other materials forand methods of making materials that are useful for the cushion insertsare disclosed in commonly owned and co-pending U.S. patent applicationSer. No. 13/208,229, filed on Aug. 11, 2011; and Ser. No. 13/271,594,filed on Oct. 12, 2011, each of which is incorporated herein byreference in its entirety. One desirable construction for the cushioninserts 30 includes a cushioning layer disposed between opposing upperand lower layers, and optional fabric layer, as described in theforegoing applications.

In addition to the foregoing, suitable materials for the foregoinglayers and the adhesive (if used) are disclosed in the afore-mentionedpatent applications, and in U.S. Publication Nos. US 2008/0034614 and US2009/0255625, which also disclose techniques for manufacturing thepresent cushion inserts; each of the foregoing publications isincorporated herein by reference in its entirety. The molds for thepresent pads are designed to allow layers to be compressed togetherunder conditions sufficient to minimize or eliminate the foam in therecessed impact regions, for certain embodiments, while allowing thelayers to bond together.

Advantages of the present improved cases include, but are not limitedto, improved impact protection, particularly on case edges and corners,lighter weight, improved aesthetics, lower manufacturing costs, and lessabrasion to the encased article. The improved cases of the presentdisclosure comprise separable inner and outer interconnected parts thatsubstantially conform to the outer surface of an article to beprotected. The protective cases can be adapted for any type of productthat requires protection, in addition to those mentioned above.

Compounds are described using standard nomenclature. For example, anyposition not substituted by an indicated group is understood to have itsvalency filled by a bond as indicated, or a hydrogen atom A dash (“—”)that is not between two letters or symbols is used to indicate a pointof attachment for a substituent. For example, —CHO is attached throughcarbon of the carbonyl group. Unless defined otherwise herein, allpercentages herein mean weight percent (“wt. %”). Furthermore, allranges disclosed herein are inclusive and combinable (e.g., ranges of“up to about 25 weight percent (wt. %), with about 5 wt. % to about 20wt. % desired, and about 10 wt. % to about 15 wt. % more desired,” areinclusive of the endpoints and all intermediate values of the ranges,e.g., “about 5 wt. % to about 25 wt. %, about 5 wt. % to about 15 wt.%”, etc.). The notation “+/−10% means that the indicated measurement maybe from an amount that is minus 10% to an amount that is plus 10% of thestated value.

Finally, unless defined otherwise, technical and scientific terms usedherein have the same meaning as is commonly understood by one of skillin the art to which this disclosure belongs.

While the disclosure has been described with reference to an exemplaryembodiment, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the disclosure. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the disclosure without departing fromthe essential scope thereof. Therefore, it is intended that thedisclosure not be limited to the particular embodiment disclosed as thebest mode contemplated for carrying out this disclosure, but that thedisclosure will include all embodiments falling within the scope of anyappended claims.

What is claimed is:
 1. A protective case, comprising: a cover having aback portion and a sidewall connected to the back portion, the covercomprising interconnected support members defined by a plurality ofreceiving apertures disposed in predetermined areas, the covercomprising a predetermined thickness; a liner having a back portion anda sidewall connected to the back portion, the liner comprising apredetermined thickness; and a cushion insert comprising raised impactregions disposed adjacent to first recessed impact regions, the raisedimpact regions disposed in predetermined areas corresponding to theplurality of receiving apertures and having a predetermined thicknessgreater than the thickness of the cover; wherein the cushion is disposedbetween the cover and the liner, such that the plurality ofinterconnected support members engage with the first recessed impactregions, and the raised impact regions engage with the plurality ofreceiving apertures, such that the raised impact regions extend abovethe outer surface of the cover.
 2. The protective case of claim 1,further comprising one or more second recessed impact regions, whereinthe thickness of the second recessed impact regions is less than thethickness of the first recessed impact regions.
 3. The protective caseof claim 2, wherein the raised impact regions comprise grooves in anupper surface thereof, such that the thickness of the grooves is lessthan the thickness of the raised impact regions, and greater than thethickness of the first recessed impact regions.
 4. The protective caseof claim 1, wherein the cushion insert comprises an impact absorbingmaterial.
 5. The protective case of claim 1, wherein the cushion insertcomprises a multi-layer laminated material.
 6. The protective case ofclaim 4, wherein the impact absorbing material is disposed betweenopposing upper and lower layers of a thermoplastic elastomeric (TPE)material.
 7. The protective case of claim 5, wherein the laminatedmaterial further comprises a reinforcing layer disposed between theimpact absorbing material and the lower layer of TPE material.
 8. Theprotective case of claim 7, wherein the laminated material furthercomprises a fabric layer disposed adjacent to the lower layer of TPEmaterial, opposite the impact absorbing material.
 9. The protective caseof claim 4, wherein the cushion insert is a rate dependent material. 10.The protective case of claim 9, wherein the rate dependent material is apolyurethane foam.
 11. The protective case of claim 1, wherein thepredetermined thickness of the raised impact regions is sufficient toabsorb impacts and/or prevent shocks from the impacts from beingtransferred to the electronic device.
 12. The protective case of claim1, wherein the case comprises an elastomeric material with a durometerof about 80 Shore A to about 100 Shore A.
 13. The protective case ofclaim 1, wherein the case comprises an elastomeric material with adurometer of about 95 Shore A.
 14. The protective case of claim 12,wherein the elastomeric material comprises a thermoplastic polyurethane.15. The protective case of claim 1, wherein the thickness of the coverranges from about 0.055″ to about 0.095″.
 16. The protective case ofclaim 1, wherein the thickness of the first recessed impact regionsranges from about 0.025″ to about 0.045″.
 17. The protective case ofclaim 2, wherein the thickness of the second recessed impact regionsranges from about 0.010″ to about 0.030″.
 18. The protective case ofclaim 1, wherein the impact absorbing regions extend above the outersurface of the cover, when the case is in an assembled configuration.19. The protective case of claim 7, wherein the reinforcing layer isporous.
 20. The protective case of claim 7, wherein the reinforcinglayer is a nonwoven fabric.
 21. The protective case of claim 7, whereinthe reinforcing layer is a hydro-entangled nonwoven fabric.
 22. Theprotective case of claim 1, wherein the cover is unitary.
 23. Theprotective case of claim 1, wherein the cushion insert is unitary. 24.The protective case of claim 1, wherein the cover is co-molded with thecushion insert.
 25. The protective case of claim 1, wherein the coverand the cushion insert are adhesively connected.
 26. The protective caseof claim 6, wherein the TPE layers are continuously bonded to the impactabsorbing material.
 27. The protective case of claim 5, wherein thecushion insert comprises a cushioning material disposed between andcontinuously bonded to opposing adjacent layers.
 28. The protective caseof claim 2, wherein, when the case is assembled, the raised impactregions are aligned with the receiving apertures.
 29. The protectivecase of claim 28, wherein, when the case is assembled, the raised impactregions are received into and at least partially through the receivingapertures and a portion of the raised impact regions extend above theupper surface of the cover.
 30. The protective case of claim 1, whereinthe case comprises an elastomeric material with a durometer ranging fromabout 80 Shore A to about 100 Shore A, and the case insert comprises arate dependent polyurethane foam with a density ranging from about 5 toabout 35 pounds per cubic foot.